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Abstract:

Switch assembly for changing the direction of current from a power source
to an appliance comprising--at least four wirings, two of the wirings are
connectable with the power source and the remaining wirings are
connectable with the appliance,--all wirings are fixed on the surface of
a substrate and none of the wirings are directly connected to each
other,--a first button comprising a first conductive pattern on one
surface of said button,--a second button comprising a second conductive
pattern on one surface of said button,--the surfaces of the buttons on
which the conductive patterns are arranged face the surface of said
substrate where the wirings are arranged,--the buttons are fixed on the
substrate--the conductive patterns on the buttons and said wirings on the
surface of the substrate are arranged in such a manner and said buttons
are placed on said substrate in such manner, that (i) said conductive
patterns on the buttons are not in contact with said wirings in an
unpressed state of the buttons, (ii) one button connects by means of the
conductive pattern in a pressed state simultaneously the first wiring of
the two wirings with one wiring of the remaining wirings and the second
wiring of the two wirings with another wiring of the remaining wirings to
enable a first current path through the switch assembly, and (iii) the
other button connects by means of the conductive pattern in a pressed
state the first wiring of the two wirings with one wiring of the
remaining wirings and the second wiring of the two wirings with another
wiring of the remaining wirings to enable a second current path through
the switch assembly being different to the first current path, wherein
further the conductive patterns comprise a composition (CO) comprising a
polymer and a conductive material dispersed in said polymer and/or a
conjugated polymer.

Claims:

1. A switch assembly (SA) for changing a direction of current from a
power source (PS) to an appliance (A), the switch assembly comprising:
four wirings, of which two wirings (W/PS) are configured to connect with
the power source (PS), and remaining wirings (W/A) are configured to
connect with the appliance (A), a substrate (S1), comprising a surface
(SF1) to which all of the wirings are fixed, a first button (B1)
comprising a first conductive pattern (CP1) on a surface (SF2') of the
first button (B1), and a second button (B2) comprising a second
conductive pattern (CP2) on a surface (SF2'') of the second button (B2),
wherein none of the four wirings are directly connected to each other,
the surfaces (SF2') and (SF2'') of the first and second buttons (B1) and
(B2) face the surface (SF1) of the substrate (S1), the buttons (B1) and
(B2) are fixed, directly or via an interlayer (IL), on the substrate
(S1), the conductive patterns (CP1) and (CP2) on the buttons (B1) and
(B2) are not in contact with the wirings when the buttons (B1) and (B2)
are in an unpressed state, when the button (B1) is in a pressed state,
the button (B1) simultaneously connects the first wiring of the two
wirings (W/PS) with one wiring of the remaining wirings (W/A) and the
second wiring of the two wirings (W/PS) with another wiring of the
remaining wirings (W/A), via the first conductive pattern (CP1), thereby
enabling a first current path through the switch assembly, and when the
button (B2) is in a pressed state, the button (B2) connects the first
wiring of the two wirings (W/PS) with one wiring of the remaining wirings
(W/A) and the second wiring of the two wirings (W/PS) with another wiring
of the remaining wirings (W/A) via the second conductive pattern (CP2),
thereby enabling a second current path through the switch assembly; the
second current path is different from the first current path, the
conductive patterns (CP1) and (CP2) comprise a composition (CO)
comprising a polymer and a conductive material dispersed in the polymer;
a conjugated polymer; or both.

2. The switch assembly (SA) of claim 1, wherein the four wirings
comprise: a composition (CO) comprising a polymer and a conductive
material dispersed in the polymer; a conjugated polymer; or both.

3. The switch assembly (SA) of claim 1, wherein (i) the conductive
patterns (CP1) and (CP2) are printed on the buttons (B1) and (B2); (ii)
the wirings are printed on the substrate (S1); or (iii) both (i) and
(ii).

4. The switch assembly (SA) of claim 1, wherein, when the button (B1) is
in a pressed state, the button (B1) simultaneously connects the first
wiring (W'/PS) of the two wirings (W/PS) with a wiring (W'/A) of the
remaining wirings (W/A), and the second wiring (W''/PS) of the two
wirings (W/PS) with another wiring (W''/A) of the remaining wirings
(W/A), via the first conductive pattern (CP1), thereby enabling the first
current path, and when the button (B2) is in a pressed state, the button
(B2) connects, via the second conductive pattern (CP2), state the first
wiring (W'/PS) of the two wirings (W/PS) with a wiring of the remaining
wirings (W/A) other than the wiring (W'/A), and connects, via the second
conductive pattern (CP2), the second wiring (W''/PS) of the two wirings
(W/PS) with a wiring of the remaining wirings (W/A) other than the wiring
(W''/A), thereby enabling the second current path.

5. The switch assembly (SA) of claim 1, wherein, when the button (B1) is
in a pressed state, the button (B1) simultaneously connects the first
wiring (W'/PS) of the two wirings (W/PS) with a first wiring (W'/A) of
the remaining wirings (W/A) and the second wiring (W''/PS) of the two
wirings (W/PS) with a second wiring (W''/A) of the remaining wirings
(W/A) to via the first conductive pattern (CP1), thereby enabling the
first current path, when the button (B2) is in a pressed state, the
button (B2) connects the first wiring (W'/PS) of the two wirings (W/PS)
with the second wiring (W''/A) of the remaining wirings (W/A), and the
second wiring (W''/PS) of the two wirings (W/PS) with the first wiring
(W'/A) of the remaining wirings (W/A) via the second conductive pattern
(CP2), thereby enabling the to second current path, the second current
path has a reversed current direction in regard to a first current
direction of the first current path, and both the first current path and
the second current path are between the power source (PS) and the
appliance (A).

6. The switch assembly (SA) of claim 1, comprising: six wirings, of which
two wirings (W/PS) are configured to connect with the power source (PS)
and remaining four wirings (W/A) are configured to connect with the
appliance (A), wherein either: (a) (i) when the button (B1) is in a
pressed state, the button (B1) simultaneously connects the first wiring
(W'/PS) of the two wirings (W/PS) with a first wiring (W'/A) of the
remaining four wirings (W/A) and the second wiring (W''/PS) of the two
wirings (W/PS) with a second wiring (W''/A) of the remaining four wirings
(W/A) via the first conductive pattern (CP1), thereby enabling the first
current path, and (ii) when the button (B2) is in a pressed state, the
button (B2) connects the first wiring (W'/PS) of the two wirings (W/PS)
with the second wiring (W''/A) of the remaining four wirings (W/A), and
the second wiring (W''/PS) of the two wirings (W/PS) with the first
wiring (W'/A) of the remaining four wirings (W/A), via the second
conductive pattern (CP2), thereby enabling the second current path, (iii)
the second current path has a reversed current direction in regard to a
first current direction of the first current path, and (iv) both the
first current path and the second current path are between the power
source (PS) and the appliance (A); or (b) (i) the first conductive
pattern (CP1) of the first button (B1) comprises, consists a first
conductive contact (CC1) and a second conductive contact (CC2), (ii) when
the button (B1) is in a pressed state, the first conductive contact (CC1)
connects the first wiring (W'/PS) of the two wirings (W/PS) with first
wiring (W'/A) of the remaining four wirings (W/A), and the second
conductive contact (CC2) connects the second wiring (W''/PS) of the two
wirings (W/PS) with the second wiring (W''/A) of the remaining four
wirings (W/A), thereby enabling the first current path, (iii) the second
button (B2) comprises a first conductive contact (CC3) and a second
conductive contact (CC4), (iv) when the button (B2) is in a pressed
state, the first conductive contact (CC3) connects the first wiring
(W'/PS) of the two wirings (W/PS) with a third wiring (W'''/A) of the
remaining four wirings (W/A), and the second conductive contact (CC4)
connects the second wiring (W''/PS) of the two wirings (W/PS) with a
fourth wiring (W''''/A) of the remaining four wirings (W/A), thereby
enabling the second current path, (v) the second current path has a
reversed current direction in regard to a first current direction of the
first current path, and (vi) both the first current path and the second
current path are between the power source (PS) and the appliance (A).

7. The switch assembly (SA) of claim 1, further comprising a second
substrate (S2), wherein the surface (SF1) of the substrate (S1) faces the
substrate (S2), the substrates (S1) and (S2) are laminated together, the
second substrate (S2) comprises two embossings, which are convex to the
surface (SF1) of the substrate (S1), the first conductive pattern (CP1)
and second conductive pattern (CP2) are fixed on a surface of the second
substrate (S2) which faces the first substrate (S1), the first conductive
pattern (CP1) is located in a first embossing of the two embossings, the
second conductive pattern (CP2) is located in a second embossing of the
two embossings the first button (B1) comprises the first conductive
pattern (CP1) with the first embossing, the second button (B2) comprises
the second conductive pattern (CP2) with the second embossing.

8. The switch assembly (SA) of claim 1, further comprising: a second
substrate (S2), and an insulation layer (IL) between the first substrate
(S1) and the second substrate (S2), wherein the surface (SF1) of the
substrate (S1) faces the insulation layer, the insulation layer (IL)
comprises two holes, the first conductive pattern (CP1) and the second
conductive pattern (CP2) are fixed on a surface of the second substrate
(S2) which faces the insulation layer (IL), the first button (B1)
comprises the first conductive pattern (CP1) above one of the two holes
in the insulation layer (IL), the second button (B2) comprises the second
conductive pattern (CP2) above the other of the two holes in the
insulation layer (IL).

9. The switch assembly (SA) of claim 1, wherein at least one of the
conductive patterns (CP1) and (CP2) comprises a composition (CO)
comprising a polymer and a conductive material dispersed in the polymer,
the polymer is at least one polymer selected from the group consisting of
a polyalkylene, a polyimide, an epoxy resin, a phenolic resin, a
polyester, a styrene-butadiene alkylene-vinyl acetate, an alkylene-vinyl
chloride copolymer, and a polyamide, and the conductive material is
selected from the group consisting of indium tin oxide, antimony tin
oxide, platinum, palladium, silver, gold, nickel, copper, carbon, and
iron.

10. The switch assembly (SA) of claim 1, wherein at least one of the
conductive patterns (CP1) and (CP2) comprises a conjugated polymer, and
the conjugated polymer is at least one polymer selected from the group
consisting of polyacetylene, polyphenylene, polyphenylene sulfide
("PPS"), polyphenylene vinylene (PPV), polypyrrole, polythiophene, and
polyaniline.

11. The switch assembly (SA) of claim 1, wherein the substrate (S1) is
selected from the group consisting of paper, cardboard, polyethylene
coated cardboard, polyethylene, polypropylene, polyester, and a polyvinyl
halide.

12. The switch assembly (SA) of claim 1, wherein power source (PS) is a
battery or a direct current (DC) source.

13. The switch assembly (SA) of claim 1, wherein the appliance (A) is
selected from the group consisting of a display, an electrical motor, and
a speaker.

14. A method of changing a direction of current in an electrical circuit
between a power source (PS) and an appliance (A), comprising changing the
direction of the current with the switch assembly of claim 1.

15. An electrical circuit, comprising: a power source (PS), an appliance
(A) and the switch assembly (SA) of claim 1, wherein the switch assembly
is configured to change a direction of current from the power source (PS)
to the appliance (A).

16. A process for preparing the switch assembly of claim 1, the process
comprising: (a) fixing the four wirings on a surface (SF1) of the first
substrate (S1); (b) printing a composition of (i) a polymer, a conductive
material, and a solvent, (ii) conjugated polymer and a solvent, or (iii)
both (i) and (ii) on a second substrate (S2), thereby obtaining the
conductive patterns (CP1) and (CP2) on one surface (SF1') of the second
substrate (S2); (c) removing the solvent, thereby adhering the conductive
patterns (CP1) and (CP2) on the surface of the substrate (S2); and (d)
either (d1) embossing the second substrate (S2) where the conductive
patterns (CP1) and (CP2) are located and laminating both substrates (S1)
and (S2) on the respective surfaces (SF1) and (SF1'), or (d2) laminating
the first substrate (S1), the second substrate (S2), and an insulation
layer (IL) comprising two holes lies between the first and second
substrate, wherein each of the conductive patterns (CP1) and (CP2) is
located above one of the holes, and each button comprises a conductive
pattern with one hole; wherein the surface (SF1) of the first substrate
(S1) faces the surface (SF1') of the second substrate (S2).

17. The switch assembly of claim 1, wherein the conductive patterns (CP1)
and (CP2) consist of: a composition (CO) comprising a polymer and a
conductive material dispersed in the polymer; a conjugated polymer; or
both.

18. The switch assembly (SA) of claim 2, wherein the wirings consist of:
a composition (CO) comprising a polymer and a conductive material
dispersed in the polymer; a conjugated polymer; or both.

19. The switch assembly (SA) of claim 1, wherein the first conductive
pattern (CP1) of the first button (B1) comprises two conductive contacts
(CC1) and (CC2), when the button (B1) is in a pressed state, the first
conductive conduct (CC1) connects the first wiring (W'/PS) of the two
wirings (W/PS) with a first wiring (W'/A) of the remaining wirings (W/A),
and the second conductive contact (CC2) connects the second wiring
(W''/PS) of the two wirings (W/PS) with a second wiring (W''/A) of the
remaining wirings (W/A), thereby enabling the first current path, the
second button (B2) comprises two conductive contacts (CC3) and (CC4),
when the button (B2) is in a pressed state, the first conductive conduct
(CC3) connects the first wiring (W'/PS) of the two wirings (W/PS) with
the second wiring (W''/A) of the remaining wirings (W/A), and the second
conductive contact (CC4) connects the second wiring (W''/PS) of the two
wirings (W/PS) with the first wiring (W'/A) of the remaining wirings
(W/A), thereby enabling the second current path, the second current path
has a reversed current direction in regard to a first current direction
of the first current path, and both the first current path and the second
current path are between the power source (PS) and the appliance (A).

20. The switch assembly of claim 6, wherein the first wiring (W'/A) and
the fourth wiring (W''''/A) of the remaining four wirings (W/A) both lead
to a first connector (C'/A) of the appliance (A), and the second wiring
(W''/A) and the third wiring (W'''/A) of the remaining four wirings (W/A)
both lead to a second connector (C'/A) of the appliance (A).

Description:

[0001] The present invention is directed to a new switch assembly for
electrical circuit as well as to its manufacture.

[0002] Switches are indispensable in electronics as they control the
current flow in electrical circuits. Typical members of the switches are
the single pole, single throw switch (SPST), the single pole, double
throw switch (SPDT), the single pole, changeover switch (SPCO), the
double pole, single throw switch (DPST), and the double pole, double
throw switch (DPDT). For instance the DPST switch is used in electrical
circuits to change polarity between a power source and the appliance. To
date only mechanical switches have been applied in this technical field.
However mechanical electrics are cost-intensive and spacious. Nowadays
efforts are undertaken to produce assemblies which are of lower
dimensions and thus space saving. Further nowadays electrochromic
displays are on the marked for which polarity change is essential
enabling to unfold their full potential.

[0003] Accordingly the object of the present invention is to provide an
electrical circuit which enables to produce electrical circuits being
cost effective and can change polarity between the power source and the
appliance. Further the electrical circuit shall be space-saving.

[0004] The finding of the present invention is that known switches enable
to change polarity between the power source and the appliance and that
they are spacious. A further finding of the present invention is that
membrane switches are of low dimensions and thus space saving.
Accordingly the present invention is directed to a switch assembly and
electrical circuits containing such a switch assembly, wherein said
switch assembly can change polarity between a power source and an
appliance and further said switch assembly is produced by print
technology.

[0005] Accordingly in a first aspect the present invention is directed to
a switch assembly (SA) for changing the direction of current from a power
source (PS) to an appliance (A) comprising [0006] at least four
wirings, preferably four or six wirings, two of the wirings (W/PS) are
connectable, preferably connected, with the power source (PS) and the
remaining wirings (W/A), i.e. preferably two or four wirings, are
connectable, preferably connected, with the appliance (A), [0007] all
wirings are fixed on the surface (SF1) of a substrate (S1) and none of
the wirings are directly connected to each other, [0008] a first button
(B1) comprising a first conductive pattern (CP1) on one surface (SF2') of
said button (B1), [0009] a second button (B2) comprising a second
conductive pattern (CP2) on one surface (SF2'') of said button (B2),
[0010] the surfaces (SF2') and (SF2'') of the buttons (B1) and (B2) on
which the conductive patterns (CP1) and (CP2) are arranged face the
surface (SF1) of said substrate (S1) where the wirings are arranged,
[0011] the buttons (B1) and (B2) are arranged, i.e. fixed, directly or by
means of an interlayer (IL) on the substrate (S1) [0012] said conductive
patterns (CP1) and (CP2) on the buttons (B1) and (B2) and said wirings on
the surface (SF1) of the substrate (S1) are arranged in such a manner and
said buttons (B1) and (B2) are placed on said substrate (S1) in such
manner, that [0013] (i) said conductive patterns (CP1) and (CP2) on the
buttons (B1) and (B2) are not in contact with said wirings in an
unpressed state of the buttons (B1) and (B2), [0014] (ii) the button (B1)
connects by means of the conductive pattern (CP1) in a pressed state
simultaneously the first wiring of the two wirings (W/PS) with one wiring
of the remaining wirings (W/A) and the second wiring of the two wirings
(W/PS) with another wiring of the remaining wirings (W/A) to enable a
first current path through the switch assembly, and [0015] (iii) the
button (B2) connects by means of the conductive pattern (CP2) in a
pressed state the first wiring of the two wirings (W/PS) with one wiring
of the remaining wirings (W/A) and the second wiring of the two wirings
(W/PS) with another wiring of the remaining wirings (W/A) to enable a
second current path through the switch assembly being different to the
first current path, wherein further the conductive patterns (CP1) and
(CP2) comprise, preferably consist of, [0016] (a) a composition (CO)
comprising a polymer and a conductive material dispersed in said polymer
and/or [0017] (b) a conjugated polymer, preferably a conducting polymer.

[0018] Preferably the switch assembly is construed in a way that [0019]
(ii) the button (B1) connects by means of the conductive pattern (CP1) in
a pressed state simultaneously the first wiring (W'/PS) of the two
wirings (W/PS) with one wiring (W'/A) of the remaining wirings (W/A) and
the second wiring (W''/PS) of the two wirings (W/PS) with another wiring
(W''/A) of the remaining wirings (W/A) to enable a first current path
through the switch assembly, and [0020] (iii) the button (B2) connects by
means of the conductive pattern (CP2) in a pressed state the first wiring
(W'/PS) of the two wirings (W/PS) with one wiring of the remaining
wirings (W/A), but being not the wiring (W'/A), preferably being not the
wirings (W'/A) and (W''/A), and the second wiring (W''/PS) of the two
wirings (W/PS) with another wiring of the remaining wirings (W/A), but
being not the wiring (W''/A), preferably being not the wirings (W'/A) and
(W''/A), to enable a second current path through the switch assembly
being different to the first current path.

[0021] In a further aspect the present invention is directed electrical
circuit comprising a power source (PS), an appliance (A) and a switch
assembly (SA) for changing the direction of current from said power
source (PS) to said appliance (A), said switch assembly (SA) comprises
[0022] at least four wirings, preferably four or six wirings, two of the
wirings (W/PS) are connected with the power source (PS) and the remaining
wirings (W/A), i.e. preferably two or four wirings, are connected with
the appliance (A), [0023] all wirings are fixed on the surface (SF1) of a
substrate (S1) and none of the wirings are directly connected to each
other, [0024] a first button (B1) comprising a first conductive pattern
(CP1) on one surface (SF2') of said button (B1), [0025] a second button
(B2) comprising a second conductive pattern (CP2) on one surface (SF2'')
of said button (B2), [0026] the surfaces (SF2') and (SF2'') of the
buttons (B1) and (B2) on which the conductive patterns (CP1) and (CP2)
are arranged face the surface (SF1) of said substrate (S1) where the
wirings are arranged, [0027] the buttons (B1) and (B2) are arranged, i.e.
fixed, directly or by means of an interlayer (IL) on the substrate (S1)
[0028] said conductive patterns (CP1) and (CP2) on the buttons (B1) and
(B2) and said wirings on the surface (SF1) of the substrate (S1) are
arranged in such a manner and said buttons (B1) and (B2) are placed on
said substrate (S1) in such manner, that [0029] (i) said conductive
patterns (CP1) and (CP2) on the buttons (B1) and (B2) are not in contact
with said wirings in an unpressed state of the buttons (B1) and (B2),
[0030] (ii) the button (B1) connects by means of the conductive pattern
(CP1) in a pressed state simultaneously the first wiring of the two
wirings (W/PS) with one wiring of the remaining wirings (W/A) and the
second wiring of the two wirings (W/PS) with another wiring of the
remaining wirings (W/A) to enable a first current direction between said
power source (PS) and said appliance (A), and [0031] (iii) the button
(B2) connects by means of the conductive pattern (CP2) in a pressed state
the first wiring of the two wirings (W/PS) with one wiring of the
remaining wirings (W/A) and the second wiring of the two wirings (W/PS)
with another wiring of the remaining wirings (W/A) to enable a reversed
current direction in regard to the first current direction between said
power source (PS) and said appliance (A), wherein further the conductive
patterns (CP1) and (CP2) comprise, preferably consist of, [0032] (a) a
composition (CO) comprising a polymer and a conductive material dispersed
in said polymer and/or [0033] (b) a conjugated polymer, preferably a
conducting polymer.

[0034] Preferably the switch assembly in the electrical circuit is
construed in a way that [0035] (ii) the button (B1) connects by means of
the conductive pattern (CP1) in a pressed state simultaneously the first
wiring (W'/PS) of the two wirings (W/PS) with one wiring (W'/A) of the
remaining wirings (W/A) and the second wiring (W''/PS) of the two wirings
(W/PS) with another wiring (W''/A) of the remaining wirings (W/A) to
enable a first current direction between said power source (PS) and said
appliance (A), and [0036] (iii) the button (B2) connects by means of the
conductive pattern (CP2) in a pressed state the first wiring (W'/PS) of
the two wirings (W/PS) with one wiring of the remaining wirings (W/A),
but being not the wiring (W'/A), preferably being not the wirings (W'/A)
and (W''/A), and the second wiring (W''/PS) of the two wirings (W/PS)
with another wiring of the remaining wirings (W/A), but being not the
wiring (W''/A), preferably being not the wirings (W'/A) and (W''/A), to
enable a reversed current direction in regard to the first current
direction between said power source (PS) and said appliance (A).

[0037] In the following the electrical circuit and the switch assembly
will be described in more detail together.

[0038] The following definitions apply throughout the present invention if
not otherwise indicated:

[0039] A "wiring" is an electrical wiring which enables to transport
current. The wiring can be typical metal cable like aluminum cable or
copper cable, the latter being preferred. However it is in particular
appreciated that the wiring is, like the conductive pattern,

(a) a composition (CO) comprising a polymer and a conductive material
dispersed in said polymer and/or (b) a conjugated polymer, preferably a
conducting polymer.

[0040] Accordingly the wiring is preferably printed on a substrate as
described in detail below.

[0041] A "conductive pattern" is a specific structure on the surface of a
substrate, in particular on the surface of the buttons. The term
"conductive pattern" indicates that the conductive material used for the
"conductive pattern" is not a metal cable, like a copper cable.
Accordingly, although the "conductive pattern" is no wiring cable it is
able to transport current.

[0042] A "conductive contact" is part of the conductive pattern.
Accordingly a conductive pattern may comprise several "conductive
contacts" being separated from each other, i.e. being not in conductive
contact. In other words between different "conductive contacts" of the
conductive pattern no current can flow. Preferably a conductive pattern
comprises, more preferably consists of, two "conductive contacts".

[0043] A "substrate" is a base material onto which a further component can
be fixed. In the present application on the "substrate" the wirings and
conductive pattern are fixed. More precisely the wirings and conductive
patterns are applied on the "substrate" by electrode pattering
technology. This technology includes deposition technology printing
technology, shadow mask technology as well as transfer technology.
Preferred technolgies are chemical vapor deposition, physical vapor
deposition, vacuum evaporation, thermal evaporation, sputtering, coating
and printing. Especially preferred aplied techniques are coating or
printing, the latter is in particular preferred. Thus, the basic material
can be any material suitable to fix, preferably to print or coat, a
conductive composition leading to the respective conductive patterns (or
wirings). Accordingly the "substrate" is preferably selected from the
group consisting of a polymer, like a polymer film or foil, paper, coated
paper, glass, and ceramic, more preferably the "substrate" is a polymer
as described in detail below.

[0044] The term "directly connected" means that two conductors are
connected to each other without any bridging element, like a switch. On
the other hand "not directly connected" means that conductors are not in
directed contact to each other but can be (conductively) connected by any
means, preferably bridging elements, like a switch.

[0045] The term "button" is an actuator, i.e. a switch, enabling to
connect unconnected wirings. Such a button can be in the form of an
un-biased switch or in the form of a biased switch, the latter being
preferred. Preferably the "button" is a "push-to-make" button, which
makes contact when the button is pressed and breaks when the button is
released. The "button" of the present invention is further preferably of
a flat structure.

[0046] A "biased switch" according to this invention is one containing a
mechanism that returns the actuator to a certain position. Typical member
is the "push-to-make" button as defined in the previous paragraph. On the
other hand "un-biased switch" remains in the adjusted position.

[0047] Each arrangement of the conductive patterns and each arrangement of
the buttons are suitable as long as the overall construction of the
switch assembly (SA) enables different current paths through it, i.e.
change in polarity between the power source (PS) and the appliance (A),
depending on the positions (on/off) of the buttons.

[0048] However it is in particular appreciated that the first conductive
pattern (CP1) of the first button (B1) comprises, consists of, two
conductive contacts (CC1) and (CC2), said first conductive conduct (CC1)
connects in a pressed state of the button (B1) the first wiring (W'/PS)
of the two wirings (W/PS) with one wiring (W'/A) of the remaining wirings
(W/A), whereas the second conductive contact (CC2) connects in a pressed
state of the button (B1) the second wiring (W''/PS) of the two wirings
(W/PS) with another wiring (W''/A) of the remaining wirings (W/A) to
enable a first current path through the switch assembly, i.e. a first
current direction between said power source (PS) and said appliance (A).

[0049] On the other hand it is preferred that the second button (B2)
comprises, consists of, two conductive contacts (CC3) and (CC4), said
first conductive conduct (CC3) connects in a pressed state of the button
(B2) the first wiring (W'/PS) of the two wirings (W/PS) with one wiring
of the remaining wirings (W/A), but being not the wiring (W'/A),
preferably being not the wirings (W'/A) and (W''/A), whereas the second
conductive contact (CC4) connects in a pressed state of the button (B2)
the second wiring (W''/PS) of the two wirings (W/PS) with another wiring
of the remaining wirings (W/A), but being not the wiring (W''/A),
preferably being not the wirings (W'/A) and (W''/A), to enable a second
current path through the switch assembly being different to the first
current path, i.e. to enable a reversed current direction in regard to
the first current direction between said power source (PS) and said
appliance (A).

[0050] Accordingly in one preferred embodiment the switch assembly (SA)
for changing the direction of current from a power source (PS) to an
appliance (A) comprises four wirings, two of the wirings (W/PS) are
connectable, preferably connected, with the power source (PS) and two
wirings (W/A) are connectable, preferably connected, with the appliance
(A), wherein [0051] the first conductive pattern (CP1) of the first
button (B1) comprises, consists of, two conductive contacts (CC1) and
(CC2), said first conductive conduct (CC1) connects in a pressed state of
the button (B1) the first wiring (W'/PS) of the two wirings (W/PS) with
the one wiring (W'/A) of the remaining two wirings (W/A), whereas the
second conductive contact (CC2) connects in a pressed state of the button
(B1) the second wiring (W''/PS) of the two wirings (W/PS) with the other
wiring (W''/A) of the remaining two wirings (W/A) to enable a first
current path through the switch assembly, i.e. to enable a first current
direction between said power source (PS) and said appliance (A), and
[0052] the second button (B2) comprises, consists of, two conductive
contacts (CC3) and (CC4), said first conductive conduct (CC3) connects in
a pressed state of the button (B2) the first wiring (W'/PS) of the two
wirings (W/PS) with the wiring (W''/A) of the remaining two wirings
(W/A), whereas the second conductive contact (CC4) connects in a pressed
state of the button (B2) the second wiring (W''/PS) of the two wirings
(W/PS) with the wiring (W'/A) of the remaining two wirings (W/A), to
enable a second current path through the switch assembly being different
to the first current path, i.e. to enable a reversed current direction in
regard to the first current direction between said power source (PS) and
said appliance (A).

[0053] In another preferred embodiment the switch assembly (SA) for
changing the direction of current from a power source (PS) to an
appliance (A) comprises six wirings, two of the wirings (W/PS) are
connectable with the power source (PS) and four wirings (W/A) are
connectable with the appliance (A), wherein [0054] the first conductive
pattern (CP1) of the first button (B1) comprises, consists of, two
conductive contacts (CC1) and (CC2), said first conductive conduct (CC1)
connects in a pressed state of the button (B1) the first wiring (W'/PS)
of the two wirings (W/PS) with one wiring (W'/A) of the remaining four
wirings (W/A), whereas the second conductive contact (CC2) connects in a
pressed state of the button (B1) the second wiring (W''/PS) of the two
wirings (W/PS) with the another wiring (W''/A) of the remaining four
wirings (W/A) to enable a first current path through the switch assembly,
i.e. to enable a first current direction between said power source (PS)
and said appliance (A), and [0055] the second button (B2) comprises,
consists of, two conductive contacts (CC3) and (CC4), said first
conductive conduct (CC3) connects in a pressed state of the button (B2)
the first wiring (W'/PS) of the two wirings (W/PS) with a third wiring
(W'''/A) of the remaining four wirings (W/A), whereas the second
conductive contact (CC4) connects in a pressed state of the button (B2)
the second wiring (W''/PS) of the two wirings (W/PS) with a fourth wiring
(W''''/A) of the remaining four wirings (W/A), to enable a second current
path through the switch assembly being different to the first current
path, i.e. a reversed current direction in regard to the first current
direction between said power source (PS) and said appliance (A), wherein
preferably further the first wiring (W'/A) and the fourth wiring
(W''''/A) of the remaining four wirings (W/A) lead to the same first
connector (C'/A) of the appliance (A) whereas the second wiring (W''/A)
and the third wiring (W'''/A) of the remaining four wirings (W/A) lead to
the same second connector (C'/A) of the appliance (A).

[0056] Two principle layer constructions of the switch assembly (SA) are
preferred

[0057] In one embodiment the switch assembly does not comprise an
interlayer (IL). Accordingly the switch assembly (SA) comprises the first
substrate (S1) and a second substrate (S2), wherein [0058] the surface
(SF1) of the substrate (S1) faces the substrate (S2), [0059] the
substrates (S1) and (S2) are laminated together, [0060] the second
substrate (S2) comprises embossings in the amount of conductive patterns,
e.g. two embossings, being convex to the surface (SF1) of the substrate
(S1), [0061] the conductive patterns, preferably the first conductive
pattern (CP1) and the second conductive pattern (CP2), are fixed on the
surface of the second substrate (S2) which faces the first substrate
(S1), [0062] each of the conductive patterns, preferably each of the two
conductive patterns (CP1) and (CP2), is located in one of the embossings,
preferably in one of the two embossings, so that each conductive pattern
forms with one embossing a button, i.e. the conductive pattern (CP1)
forms with one embossing the button (B1) and the conductive pattern (CP2)
forms with the other embossing the button (B2).

[0063] In the other embodiment the switch assembly comprises an interlayer
(IL), i.e. an insulation layer. Accordingly the switch assembly (SA)
comprises the first substrate (S1), an interlayer (IL), i.e. an
insulation layer, and a second substrate (S2), [0064] the surface (SF1)
of the substrate (S1) faces the interlayer (IL), i.e. the insulation
layer, [0065] the interlayer (IL), i.e. the insulation layer, is between
the first substrate (S1) and the second (S2) substrate, [0066] the
insulation layer (IL) comprises holes in the amount of conductive
patterns, i.e. preferably two holes, [0067] the conductive patterns,
preferably the first conductive pattern (CP1) and the second conductive
pattern (CP2), are fixed on the surface of the second substrate (S2)
which faces the insulation layer (IL), [0068] each of the conductive
patterns, preferably the two conductive patterns (CP1) and (CP2), is
located above one of the holes, so that each of the conductive patterns
forms with one hole a button, i.e. preferably the conductive pattern
(CP1) forms with one hole the button (B1) and the conductive pattern
(CP2) forms with the other hole the button (B2).

[0069] As stated above the conductive patterns, i.e. the first conductive
pattern (CP1) and the second conductive pattern (CP2), and preferably
also the wirings are printed on the substrates. Accordingly it is
appreciated that the conductive patterns, i.e. the first conductive
pattern (CP1) and the second conductive pattern (CP2), and optionally the
wirings comprise, preferably consist of, [0070] (a) a composition (CO)
comprising a polymer and a conductive material dispersed in said polymer
and/or [0071] (b) a conjugated polymer, preferably a conducting polymer.

[0072] The composition (CO) preferably comprises a conductive material
selected from the group consisting of silver, silver alloy, gold, gold
alloy, aluminium, aluminium alloy, nickel, nickel alloy, platinum,
platinum alloy, palladium, palladium alloy, copper, copper alloy, carbon,
iron, iron alloy, indium tin oxide (ITO), antimony tin oxide (ATO), and
mixtures thereof, more preferably silver. Within the scope of conductive
material is also a conductor-coated material such as organic polymer
particles coated by silver, copper or nickel. In a preferred embodiment
the conductive material is in fine flake particle form. The predominant
portion of the conductive material has an average particle size in the
range from about one to about ten microns. Based upon the total weight of
the composition (CO), the conductive material lies in the range from 30
to 80 wt.-%. More preferably, the conductive material lies in the range
from 60 to 65 wt.-%. The remainder constitutes the polymer material of
the composition.

[0073] So long as at least 30 wt.-% of the composition is conductive
material, up to a maximum 40 wt.-% nonconductive filler particles can be
used. Materials which can be used for this purpose include glass beads,
clay and polymers which are insoluble in a polar solvent.

[0076] The term "conjugated polymer" according to this invention is
understood according to the definition of IUPAC (2nd Edition (1997)).
Accordingly a "conjugated polymer is preferably a polymer system whose
structure is represented by alternating single and double bonds, like
--CH2═CH--CH═CH2--. In such a system, conjugation is
the interaction of one p-orbital with another across an intervening
s-bond in such structures. (In appropriate molecular entities d-orbitals
may be involved.) The term is also extended to the analogous interaction
involving a p-orbital containing an unshared electron pair, e.g.:
Cl-CH═CH2. Preferably the conjugated polymer is a conductive
polymer. The term "conductive polymer" is understood as according to the
definition of IUPAC (2nd Edition (1997)). Thus a conudctive polymer is a
polymer that exhibits bulk electric conductivity. Therefore the
conjugated polymer, preferably the conductive polymer, is preferably
selected from the group consisting of polymerized anthracenes,
polymerized perylenes, polyaromatic hydrocarbons, polyacetylene,
polyphenylene, polyphenylene sulfide ("PPS"), polyphenylene vinylene
(PPV), polypyrrole, polythiophene, and polyaniline. It is especially
preferred that the conjugated polymer is the polythiophene. An preferred
commercial product is polyethylenedioxythiophene:polystyrenesulphonate,
(PE-DOT:PSS) or mixtures thereof like PSS in PEDOT:PSS.

[0077] The composition (CO) and/or the conjugated polymer may be dissolved
for applying it/them on the substrate. The solvent used can be any
solvent dependent on the induvidual polymer used. For instance
polythiophene and polyaniline are usually dissolved in toluene,
chloroform, o-dicholorobenzene and other similar solvents. Polyaniline is
in particular available as toluene and water-based solutions, like the
commercial products Panipol T and Panipol W. Such mentioned solvents are
preferably sufficiently volatile that it can be vaporized from the
composition (CO) and/or the conjugated polymer below the thermal
degradation temperature of the substrate. Such materials include esters,
alcohols, acetates and ethers as well as halogenated aromatics and
non-halogenated aromatics, like toluene, xylene and tetraline. Though
halogenated aromatics such o-dichlorobenzene are fully operable in the
invention, they are not preferred because of the health hazards which may
be associated with them. Preferred solvents therefore include materials
such as toluene, tetraline, ethylene glycol phenyl ether, benzyl alcohol,
glycol ether acetates, and carbitol acetate. Carbitol acetate is
especially preferred and most preferred is toluene. Mixtures of various
solvents will frequently be used in order to adjust the volatility of the
solvent component of the organic medium.

[0078] In general, the boiling point of the solvent component(s) should be
no less than 100° C. 150° C. A boiling point range of from
105 to 220° C. is preferred. Within this range the volatility of
the solvent will be selected in consideration of the method of solvent
removal and/or fabrication. For example, when the high speed reel-to-reel
procedure is used it is essential that the solvent be removed quite
rapidly during processing. In either case the solvent removal is
ordinarily accelerated by mildly heating the printed substrate.
Typically, the substrate is heated in a hot air oven to 70 to 120°
C. when using more volatile solvents in the reel-to-reel process and 90
to 140° C. when using less volatile solvents in the semiautomatic
processes.

[0079] The material used in the present application for the substrates is
preferably selected from the group consisting of paper, cardboard,
cellulose derivatives (cellulose acetates, nitrates, esters),
carboxymethyl cellulose (CMC), polyimide (Kapton), polysulfone,
polyethersulfone, polyacrylonitrile, polyamide, polyacrylates (PMMA),
PTFE, PVDF polyethylene, polypropylene, polyester, and polyvinyl halides.
Material for the substrate (S1) and (S2) can be different, but it is
appreciated that it is the same.

[0080] Further any power source (PS) is applicable for the present
invention, however it is preferred that it produces direct current. Thus
in a preferred embodiment the power source is a battery. The appliance
(A) can be of any type. However preferred appliances are those operated
by direct current (DC), like displays, like electrochromic displays or
electrochemical displays, electrical motors and electrical testing
devices. In case of alternating current (AC) the appliance can be for
instance a speaker

[0081] FIG. 1 and FIG. 1a illustrate a first preferred embodiment of a
button of a switch assembly (SA) (released and pressed state) comprising
an interlayer (IL).

[0082] FIG. 2 and FIG. 2a illustrate a second preferred embodiment of a
button of a switch assembly (SA) (released and pressed state).

[0083]FIG. 3 shows a schematic assembly of a facility to produce a switch
assembly (SA) according to FIG. 1 and FIG. 1a.

[0084]FIG. 4. shows a schematic assembly of a facility to produce a
switch assembly (SA) according to FIG. 2 and FIG. 2a

[0085]FIG. 5a, FIG. 5b, and FIG. 5c show a schematic electrical circuit
including a switch assembly (SA) according to this invention.

[0086] In the following a switch assembly according to FIG. 1 and FIG. 1a
will be described in more detail.

[0087] FIG. 1 and FIG. 1a are cross sections of a button (released and
pressed state) which comprises a first substrate (S1), an interlayer
(IL), i.e. an insulation layer, and a second substrate (S2), said
interlayer (IL) is between the first substrate (S1) and the second (S2)
substrate. The substrates can be paper, cardboard or a polymer. The
insulation layer is preferably a polymer material. Even more preferred
the interlayer (IL) is an insulating (dielectric) material, like PET,
PEN, polyimide, or PMMA. On the other hand the substrates (S1) and (S2)
are polyethylene coated cardboard. Further one surface of the substrate
(S1) faces the interlayer (IL), i.e. the insulation layer, and the
insulation layer (IL) contains a hole (H1). The substrate (S1) as well as
the substrate (S2) is laminated on the interlayer (IL) and thus a hollow
space is formed by the hole (H1) and the two substrates. A conductive
pattern (not shown) is fixed on the surface of the second substrate (S2)
which faces the insulation layer (IL) and is located above the hole, so
that the conductive pattern forms with the hole the button. Opposite to
the conductive pattern wirings (not shown) are fixed on the substrate
(S1). Thus in case the button is pushed (FIG. 1a) the conductive pattern
comes in contact with the wirings on the substrate (S1) enabling a
current flow. In case the button is released (FIG. 1) the conductive
pattern and the wirings are unconnected.

[0088] As shown in FIG. 3 the wirings are printed on the substrate (S1) by
passing the substrate (S1) over a rotating drum (D1). The surface of the
drum (D1) shows as specific pattern, which is wetted with a conductive
ink as the drum (D1) rotates through an ink bath (IB1). When passing the
substrate (S1) over the wetted the drum (D1) the pattern of the drum is
displayed as the wiring pattern on the substrate (S1). Of course also
other techniques are applicable, like rotary screen (the ink is in the
roll and it is squeeged through patterned screens), flexography
(photocurable rubber roll with patterns between drum (D1, anilox roll)
and substrate (S1) which tranfers ink to the substrate), and inkjet
printing technique (inkjet print head instead of roll). Simultaneously a
conductive pattern is printed on the substrate (S2) by passing the
substrate (S2) over a second rotating drum (D2). The surface of the drum
(D2) shows as specific pattern (different to the pattern of drum (D1)),
which is wetted with a conductive ink as the drum (D2) rotates through an
ink bath (1B2). When passing the substrate (S2) over the wetted drum (D2)
the pattern of the drum is displayed as the conductive pattern on the
substrate (S2). Afterwards the wirings and conductive pattern,
respectively, are fixed on the substrates by passing the substrates
through an oven/drying assembly (thermal curing, infrared curing, UV
curing and/or washing bath) removing the solvent from the ink.
Subsequently the printed surface of substrate (S2) is covered with an
interlayer (IL) with punched openings and both the substrate (S1) and the
substrate (S2) covered with the interlayer (IL) are guided to the
lamination unit in a way that the printed surfaces of the substrate (S)
face each the interlayer (IL).

[0089] FIG. 2 and FIG. 2a are cross sections of a button (released and
pressed state) which comprises a first substrate (S1) and a second
substrate (S2) being laminated together. The substrates (S1) and (S2) can
be for instance polyethylene coated cardboards. The second substrate (S2)
comprises an embossing being convex to the surface of the substrate (S1).
A conductive pattern (not shown) being fixed on the surface of the second
substrate (S2) which faces the first substrate (S1) and being located in
the embossing forms a button. Further the embossing of the substrate (S2)
with the surface of the substrate (S1) facing the substrate (S2) form a
hollow space. Opposite to the conductive pattern wirings (not shown) are
fixed on the substrate (S1). Thus in case the button is pushed (FIG. 2a)
the conductive pattern comes in contact with the wirings on the substrate
(S1) enabling a current flow. In case the button is released (FIG. 2) the
conductive pattern and the wirings are unconnected.

[0090] As shown in FIG. 4 the wirings are printed on the substrate (S1) by
passing the substrate (S1) over a rotating drum (D1). The surface of the
drum (D1) shows as specific pattern, which is wetted with a conductive
ink as the drum (D1) rotates through an ink bath (IB1). When passing the
substrate (S1) over the wetted drum (D1) the pattern of the drum is
displayed as the wiring pattern on the substrate (S1). Also here other
printing methods and arrangements are possible. Reference is made to
those mentioned above. Simultaneously a conductive pattern is printed on
the substrate (S2) by passing the substrate (S2) over a second rotating
drum (D2). The surface of the drum (D2) shows as specific pattern
(different to the pattern of drum (D1)), which is wetted with a
conductive ink as the drum (D2) rotates through an ink bath (1B2). When
passing the substrate (S2) over the wetted the drum (D2) the pattern of
the drum is displayed as the conductive pattern on the substrate (S2).
Afterwards the wirings and conductive pattern, respectively, are fixed on
the substrates by passing the substrates through an oven/drying assembly
(thermal curing, infrared curing, UV curing and/or washing bath) removing
the solvent from the ink. Subsequently the printed surface of substrate
(S2) is guided over a further drum (D3) having protrusions initiating
embossings in the substrate 2 and both the substrate (S1) and the
substrate (S2) are guided to the lamination unit in a way that the
printed surfaces of the substrates face each other.

[0091] In FIG. 5a, FIG. 5b and FIG. 5c show an electrical circuit
comprising a power source (PS), an appliance (A), namely a
electrochemical device or lectrochromic device (display), and a switch
assembly (SA) for changing the direction of current from said power
source (PS) to said appliance (A), said switch assembly (SA) comprises
six wirings, two of the wirings (W'/PS) and (W''/PS) are connected with
the power source (PS) and the remaining four wirings (W'/A), (W''/A),
(W'''/A) and (W''''/A), are connected with the appliance (A), wherein the
wirings (W'/A) and (W''''/A) lead to one connection port of the appliance
(A) whereas the wirings (W''/A) and (W'''/A) lead to the other connection
port of the appliance (A). Further all wirings are fixed on a surface
(SF1) of a substrate (S1) (not shown) and none of the wirings are
directly connected to each other. The switch assembly (A) comprises
further a first button (B1) comprising a first conductive pattern (CP1)
on one surface (SF2') of said button (B1), wherein the conductive pattern
(CP1) consists of two conductive contacts (CC1) and (CC2). Additionally
the switch assembly comprises a second button (B2) comprising a second
conductive pattern (CP2) on one surface (SF2'') of said button (B2),
wherein the conductive pattern (CP2) consists of two conductive contacts
(CC3) and (CC4). The surfaces (SF2') and (SF2'') of the buttons (B1) and
(B2) on which the conductive patterns (CP1) and (CP2) are arranged face
the surface (SF1) of said substrate (S1) where the wirings are arranged.
The buttons (B1) and (B2) are preferably fixed on the substrate (S1) as
shown in FIGS. 1, 1a, 2, and 2a. As can be seen in particular in FIGS. 5b
and 5c the conductive patterns (CP1) and (CP2) (including the conductive
contacts (CC1) to (CC4)) on the buttons (B1) and (B2) and said wirings on
the surface (SF1) of the substrate (S1) are arranged in such a manner and
said buttons (B1) and (B2) are placed on said substrate (S1) in such
manner, that

the button (B1) connects [0092] (a) by means of the conductive contact
(CC1) of the conductive pattern (CP1) in a pressed state the first wiring
(W'/PS) with the wiring (W'/A) and [0093] (b) by means of the conductive
contact (CC2) of the conductive pattern (CP1) in a pressed state the
second wiring (W''/PS) with the wirings (W''/A) [0094] to enable a first
current direction between said power source (PS) and said appliance (A),
and the button (B2) connects [0095] (c) by means of the conductive
contact (CC3) of the conductive pattern (CP2) in a pressed state the
first wiring (W'/PS) with the wiring (W'''/A) and [0096] (d) by means of
the conductive contact (CC4) of the conductive pattern (CP2) in a pressed
state the second wiring (W''/PS) with the wiring (W''''/A) to enable a
reversed current direction in regard to the first current direction
between said power source (PS) and said appliance (A).

[0097] The invention is not only directed to the switch assembly (SA) and
the electric circuit as defined in the present invention, but also to the
use of the instant switch assembly (SA) in an electrical circuit.

[0098] The invention will be now described in more detail by way of
examples.

EXAMPLES

Example 1

R2R Screen Printing of Silver Ink on Single Substrate

[0099] Roll of polyethylene-coated cardboard (S1) (Performa Nature PE,
Stora Enso) was installed to unwinder and guided through printing unit
(D1) and drying oven to a rewinder unit. Rotary screen printing unit (D1)
with patterned 230L cylinder having a ink laydown 8 μm and mesh width
56 μm was loaded with Ciba Xymara Electra SSB-111 conductive silver
ink. The pattern in the screen cylinder corresponds to conductive wiring
and buttons to be printed on substrate. Buttons were printed as mirrored
image on the substrate in the way that when substrate is folded buttons
and wirings are positioned to form the polarity switch device. The web
speed was set to 2 m/min and drying temperature of oven was set to
120° C. The measured film thickness of printed silver was
˜11 μm and RMS roughness was ˜1.5 μm. Sheet resistivity
of printed silver was ˜20 mΩ/quadrature which was measured
using 4-probe measurement at probe distance of 1 cm.

Example 2

R2R Screen Printing of Silver Ink on Single Substrate Using Spacer

[0100] Roll of polyethylene-coated cardboard (S2) (Performa Nature PE,
Stora Enso) was installed to unwinder and guided through printing unit
(D2) and drying oven to a rewinder unit. Rotary screen printing unit (D2)
with patterned 230L cylinder having a ink laydown 8 μm and mesh width
56 μm was loaded with Ciba Xymara Electra SSB-111 conductive silver
ink. The pattern in the screen cylinder corresponds to conductive wiring
and buttons to be printed on substrate. Buttons were printed as mirrored
image on the substrate in the way that when substrate is folded buttons
and wirings are positioned to form the polarity switch device. The
substrate (S2) was combined with lamination unit that attach polyethylene
terephtalate (IL) (PET, Melinex 401, DuPont, thickness 50 μm) on
substrate (S2). Prior to lamination the PET substrate (IL) was guided
through die-cutter which punches holes to form corresponding windows for
buttons. The web speed was set to 2 m/min and drying temperature of oven
was set to 120° C. The measured film thickness of printed silver
was ˜11 μm and RMS roughness was ˜1.5 μm. Sheet
resistivity of printed silver was ˜20 mΩ/quadrature which
was measured using 4-probe measurement at probe distance of 1 cm.

Example 3

R2R Screen Printing of Silver Ink on Single Substrate with Embossing

[0101] Roll of polyethylene-coated cardboard (S2) (Performa Nature PE,
Stora Enso) was installed to unwinder and guided through printing unit
(D2), drying oven and embossing unit (D3) to a rewinder unit. Rotary
screen printing unit (D2) with patterned 230L cylinder having a ink
laydown 8 μm and mesh width 56 μm was loaded with Ciba Xymara
Electra SSB-111 conductive silver ink. The pattern in the screen cylinder
(D2) corresponds to conductive wiring and buttons to be printed on
substrate (S2). The embossing unit (D3) deforms the substrate (S2) only
where buttons were printed. Buttons were printed as mirrored image on the
substrate in the way that when substrate is folded buttons and wirings
are positioned to form the polarity switch device. The web speed was set
to 2 m/min and drying temperature of oven was set to 120° C. The
measured film thickness of printed silver was ˜11 μm and RMS
roughness was ˜1.5 μm. Sheet resistivity of printed silver was
˜20 mΩ/quadrature which was measured using 4-probe
measurement at probe distance of 1 cm.

Example 4

R2R Screen Printing of Silver Ink on Two Substrates with Embossing

[0102] Rolls of polyethylene-coated cardboard (S1, S2) (Performa Nature
PE, Stora Enso) were installed to two separate unwinders and guided
through printing units (D1, D2) and drying ovens via common lamination
unit to common rewinder unit. The other cardboard substrate (S2), which
was used for printing buttons were also guided through embossing unit
(D3), which was positioned after drying oven. Rotary screen printing
units (D1, D2) with patterned 230L cylinders having a ink laydown 8 μm
and mesh width 56 μm was loaded with Ciba Xymara Electra SSB-111
conductive silver ink. The pattern in the other rotary screen cylinder
(D1) corresponds to conductive wiring and in other rotary screen cylinder
(D2) to buttons, respectively. Both screen printing unit cylinders were
positioned in the way that laminated wiring and buttons forms a polarity
switch device. The embossing unit (D3) deforms the substrate to form
buttons on the location where buttons were printed. The web speed was set
to 2 m/min and drying temperature of oven was set to 120° C. The
measured film thickness of printed silver was ˜11 μm and RMS
roughness was ˜1.5 μm. Sheet resistivity of printed silver was
˜20 mΩ/quadrature which was measured using 4-probe
measurement at probe distance of 1 cm. Lamination unit combines and glues
the both button and wiring substrates in to a rewinder to form a roll of
polarity switch devices.

Example 5

R2R Screen Printing of Silver Ink on Two Different Substrates with
Embossing

[0103] Roll of polyethylene-coated cardboard (S2) (Performa Nature PE,
Stora Enso) were installed to unwinder and guided through printing unit
(D2) and drying oven via common lamination unit to common rewinder unit.
Roll of polyethylene terephtalate (S1) (PET, 3M, thickness 125 μm) was
installed to other unwinder and guided through printing unit (D1) and
drying oven via common lamination to common rewinder unit with cardboard
substrate. The cardboard substrate (S2), which was used for printing
buttons were also guided through embossing unit (D3). Rotary screen
printing units with patterned 230L cylinders having a ink laydown 8 μm
and mesh width 56 μm was loaded with Ciba Xymara Electra SSB-111
conductive silver ink. The pattern in the screen cylinder (D1) for PET
corresponds to conductive wiring and in screen cylinder (D2) for
cardboard corresponds to buttons. Both screen printing unit cylinders
were positioned in the way that laminated wiring and buttons forms a
polarity switch device. The embossing unit (D3) deforms the cardboard
substrate to form buttons and the embossing cylinder was positioned in
the way that deformation occurs on printed silver after drying oven. The
web speed was set to 2 m/min and drying temperature of oven was set to
120° C. The measured film thickness of printed silver was 11 μm
and RMS roughness was 1.5 μm. Sheet resistivity of printed silver was
20 mΩ/quadrature which was measured using 4-probe measurement at
probe distance of 1 cm. Lamination unit combines and glues the both
button and wiring substrates in to a rewinder to form a roll of polarity
switch devices.

Example 6

R2R Screen Printing of Silver Ink on Two Substrates Using Spacer

[0104] Rolls of polyethylene-coated cardboard (S1, S2) (Performa Nature
PE, Stora Enso) were installed to two separate unwinders and guided
through printing units (D1, D2) and drying ovens via common lamination
unit to common rewinder unit. The other substrate (S2), which was used
for printing buttons were combined with lamination unit that attach
polyethylene terephtalate (IL) (PET, Melinex 401, DuPont, thickness 50
μm) on cardboard substrate (S2). The PET substrate (IL) was guided
through die-cutter which punches holes to form corresponding windows for
buttons. Rotary screen printing units with patterned 230L cylinders
having a ink laydown 8 μm and mesh width 56 μm was loaded with Ciba
Xymara Electra SSB-111 conductive silver ink. The pattern in the other
screen cylinder (D1) corresponds to conductive wiring and in other screen
cylinder (D2) to buttons. Screen printing unit cylinders (D1, D2) and
lamination unit for die-cutted spacer material (IL) were positioned in
the way that laminated end-product with wiring and buttons forms a
polarity switch device. The web speed was set to 2 m/min and drying
temperature of oven was set to 120° C. The measured film thickness
of printed silver was 11 μm and RMS roughness was 1.5 μm. Sheet
resistivity of printed silver was 20 mΩ/quadrature which was
measured using 4-probe measurement at probe distance of 1 cm. The common
lamination unit combines and glues the both button and wiring substrates
in to a rewinder to form a roll of polarity switch devices.

Example 7

R2R Screen Printing of Silver Ink on all Plastic Substrates Using Spacer

[0105] Rolls of polyethylenenaphtalene (S1, S2) (PEN, Teonex Q51, Dupont
teijing films, thickness 50 μm) were installed to two separate
unwinders and guided through printing units (D1, D2) and drying ovens via
common lamination unit to common rewinder unit. The other substrate (S2),
which was used for printing buttons were combined with lamination unit
that attach polyethylene terephtalate (IL) (PET, Melinex 401, DuPont,
thickness 50 μm) on cardboard substrate (S2). The PET substrate (IL)
was guided through die-cutter which punches holes to form corresponding
windows for buttons. Rotary screen printing units with patterned 230L
cylinders having a ink laydown 8 μm and mesh width 56 μm was loaded
with Ciba Xymara Electra SSB-111 conductive silver ink. The pattern in
the other screen cylinder (D1) corresponds to conductive wiring and in
other screen cylinder (D2) to buttons. Screen printing unit cylinders
(D1, D2) and lamination unit for die-cutted spacer material (IL) were
positioned in the way that laminated end-product with wiring and buttons
forms a polarity switch device. The web speed was set to 2 m/min and
drying temperature of oven was set to 120° C. The measured film
thickness of printed silver was 11 μm and RMS roughness was 1.5 μm.
Sheet resistivity of printed silver was 20 mΩ/quadrature which
was measured using 4-probe measurement at probe distance of 1 cm. The
common lamination unit combines and glues the both button and wiring
substrates in to a rewinder to form a roll of polarity switch devices.

Example 8

R2R Inkjet Printing of Silver Ink on One Plastic Substrate Using Spacer

[0106] Roll of polyethylenenaphtalene (S2) (PEN, Teonex Q51, Dupont
teijing films, thickness 50 μm) was installed to unwinder and guided
through printing unit (D2) and drying ovens via lamination unit to
rewinder unit. The substrate (S2) was combined with lamination unit that
attach polyethylene terephtalate (IL) (PET, Melinex 401, DuPont,
thickness 50 μm) on substrate (S2). The PET substrate (IL) was guided
through die-cutter which punches holes to form corresponding windows for
buttons. Inkjet unit having Spectra SQ128 printhead was loaded with Cabot
CCl-300 conductive nanosilver ink. The printed pattern corresponds to
conductive wirings and buttons. Buttons were printed as mirrored image on
the substrate in the way that when substrate is folded buttons and
wirings are positioned to form the polarity switch device. Die-cutted
spacer material (IL) were positioned in the way that folded end-product
with wiring and buttons forms a polarity switch device. The web speed was
set to 6 m/min and drying temperature of oven was set to 140° C.
Sheet resistivity of printed silver was 40 mΩ/quadrature which
was measured using 4-probe measurement at probe distance of 1 cm.

Example 9

R2R Flexography Printing of Polyaniline on all Plastic Substrates Using
Spacer

[0108] The pattern in the other flexography cylinder (D1) corresponds to
conductive wiring and in other flexography cylinder (D2) to buttons.
Flexography printing unit cylinders (D1, D2) and lamination unit for
die-cutted spacer material (IL) were positioned in the way that laminated
end-product with wiring and buttons forms a polarity switch device. The
web speed was set to 40 m/min and drying temperature of oven was set to
140° C. The measured film thickness of printed polyaniline was
0.45 μm. Sheet resistivity of printed polyaniline was 120
mΩ/quadrature which was measured using 4-probe measurement at
probe distance of 1 cm. The common lamination unit combines and glues the
both button and wiring substrates in to a rewinder to form a roll of
polarity switch devices.

Example 10

R2R Gravure Printing of Polyaniline on all Plastic Substrates Using Spacer

[0109] Rolls of polyethyleneterehtalene (S1, S2) (PET, 3M, thickness 125
μm) were installed to two separate unwinders and guided through
gravure printing units (D1, D2) and drying ovens via common lamination
unit to common rewinder unit. The other substrate (S2), which was used
for printing buttons were combined with lamination unit that attach
polyethylene terephtalate (IL) (PET, Melinex 401, DuPont, thickness 50
μm) on cardboard substrate (S2). The PET substrate (IL) was guided
through die-cutter which punches holes to form corresponding windows for
buttons. Gravure printing unit was loaded with Panipol T conductive
polyaniline ink. The pattern in the other gravure cylinder (D1)
corresponds to conductive wiring and in other gravure cylinder (D2) to
buttons.

[0110] Gravure printing unit cylinders (D1, D2) and lamination unit for
die-cutted spacer material (IL) were positioned in the way that laminated
end-product with wiring and buttons forms a polarity switch device. The
web speed was set to 100 m/min. Sheet resistivity of printed polyaniline
was 120 mΩ/quadrature which was measured using 4-probe
measurement at probe distance of 1 cm. The common lamination unit
combines and glues the both button and wiring substrates in to a rewinder
to form a roll of polarity switch devices.